U.S. patent application number 11/892021 was filed with the patent office on 2008-07-03 for environmental control and power system.
Invention is credited to Gerald Allen Alston.
Application Number | 20080161974 11/892021 |
Document ID | / |
Family ID | 39585118 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080161974 |
Kind Code |
A1 |
Alston; Gerald Allen |
July 3, 2008 |
Environmental control and power system
Abstract
A self-contained environmental control and power system (ECAPS)
unit including an HVAC system with at least one variable-speed
compressor driven by a DC motor, wherein the HVAC system is adapted
to condition air and output the conditioned air and a
variable-speed diesel engine connected to a generator. The
generator is configured to vary in speed so as to output AC power
at a variable frequency. The unit includes a rectification assembly
which transforms the AC power from the generator and/or external AC
power to DC power, and an inverter assembly which transforms the DC
power to an export AC power. The ECAPS unit directs the DC power to
the DC motor to drive the variable speed compressor and varies, in
a controlled manner, at least one parameter of the outputted
conditioned air from the HVAC system.
Inventors: |
Alston; Gerald Allen;
(Oakland, CA) |
Correspondence
Address: |
FOLEY AND LARDNER LLP;SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Family ID: |
39585118 |
Appl. No.: |
11/892021 |
Filed: |
August 17, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60822717 |
Aug 17, 2006 |
|
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Current U.S.
Class: |
700/276 ;
290/40A; 417/32; 417/364; 417/423.1 |
Current CPC
Class: |
Y02B 30/741 20130101;
Y02B 30/70 20130101; F25B 2327/001 20130101; F04B 35/00 20130101;
F25B 2600/0253 20130101; F25B 27/00 20130101 |
Class at
Publication: |
700/276 ;
417/423.1; 417/364; 290/40.A; 417/32 |
International
Class: |
F24F 11/00 20060101
F24F011/00; F04B 17/00 20060101 F04B017/00; G05D 23/19 20060101
G05D023/19; F24F 1/02 20060101 F24F001/02 |
Claims
1. An environmental control and power system (ECAPS) unit,
comprising: an HVAC system with at least one variable-speed
compressor driven by a first DC motor, wherein the HVAC system is
adapted to condition air and output the conditioned air; a
variable-speed diesel engine; a first generator mechanically
coupled to the diesel engine and adapted to vary in speed so as to
output first AC power at a variable frequency, the first generator
being a three-phase permanent magnet generator; a first
rectification assembly adapted to transform the first AC power from
the generator and/or external AC power to a first DC power; and a
first inverter assembly adapted to transform the first DC power to
an export AC power; wherein the ECAPS unit is adapted to direct the
first DC power to the first DC motor to drive the variable speed
compressor; wherein the ECAPS unit is adapted to vary, in a
controlled manner, at least one parameter of the outputted
conditioned air; and wherein the ECAPS unit is a self-contained
unit.
2. The ECAPS unit of claim 1, wherein the first DC motor is a
brushless DC motor.
3. The ECAPS unit of claim 1, wherein the first DC motor is a
permanent magnet motor.
4. The ECAPS unit of claim 1, wherein the first rectification
assembly is configured to also transform the first AC power and/or
external AC power to a second DC power, wherein the second DC power
is at a substantially lower voltage than a voltage of the first DC
power.
5. The ECAPS unit of claim 1, further comprising a second generator
mechanically coupled to the diesel engine, wherein the second
generator is configured to output power at a substantially lower
voltage than a voltage of the first AC power.
6. The ECAPS unit of claim 5, wherein at least one of: (i) the
power outputted from the second generator is AC power, and the
first rectification assembly is adapted to transform the power
outputted from the second generator to DC power; (ii) the power
outputted from the second generator is AC power, and the ECAPS unit
includes a second rectification assembly, the second rectification
assembly being adapted to transform the power outputted from the
second generator to DC power; and (iii) the power outputted from
the second generator is DC power.
7. The ECAPS unit of claim 1, wherein the diesel engine is a
three-cylinder turbo-charged common rail injection aluminum
engine.
8. The ECAPS unit of claim 1, wherein the first generator is a
permanent magnet alternator having a capacity about the same as
that of the diesel engine.
9. The ECAPS unit of claim 5, wherein the first generator has eight
magnetic poles of neodymium material and is wound on twelve
slots.
10. The ECAPS unit of claim 1, wherein the ECAPS unit includes at
least one power buss circuit which directs the first DC power to
high voltage loads of the HVAC system including: one or more
variable-speed air conditioning compressor motors, one of which is
the variable speed compressor DC motor; one or more variable speed
condenser fan motors; and one or more variable-speed evaporator fan
motors.
11. The ECAPS unit of claim 1, wherein the one or more
variable-speed air conditioning compressors, the one or more
variable speed condenser fans, and the one or more variable-speed
evaporator fans are powered by permanent magnet brushless DC
motors.
12. The ECAPS unit of claim 1, wherein the ECAPS unit is adapted to
produce a second DC power, wherein the second DC power is at a
substantially lower voltage than a voltage of the first DC power,
wherein the ECAPS unit includes at least two power buss circuits
which respectively carry the first and second DC powers to internal
loads of the ECAPS unit at substantially higher and lower voltage
levels.
13. The ECAPS unit of claim 12, wherein all of the internal loads
of the ECAPS unit are powered from DC power produced by the ECAPS
unit, the DC power produced by the ECAPS unit including the first
DC power and the second DC power.
14. The ECAPS unit of claim 1, wherein the first inverter assembly
transforms the first DC power to the export AC power such that the
export AC power is a sine wave at least one of 115, 120, 220, 230
and 240 volts and at least one of about 50 hz, 60 hz and 400
hz.
15. The ECAPS unit of claim 1, wherein the HVAC has a capacity of
0-40 kw in heating mode and 5,000-to 60,000 BTU/hr in cooling
mode.
16. The ECAPS unit of claim 1, further comprising a liquid-air heat
exchanger adapted to dissipate heat from the engine and the first
generator so as to decrease the external thermal signature of the
ECAPS unit, wherein heated components of the heat exchanger are
radiatively shielded from the outside of the ECAPS unit and the
ECAPS unit is adapted to direct cooling air discharged from the
heat exchanger in a manner to prevent external components of the
ECAPS unit from heating above an ambient temperature due to the
discharged cooling air.
17. The ECAPS unit of claim 16, further comprising an exhaust
system configured to exhaust combustion gases from the diesel
engine in a manner that decreases acoustic noise and decreases the
external thermal signature of the ECAPS unit, wherein heated
components of the exhaust system are radiatively shielded from the
outside of the ECAPS unit and the ECAPS unit is adapted to
discharge combustion gases exhausted from the ECAPS unit in a
manner to prevent external components of the ECAPS unit from
heating above an ambient temperature due to the discharged
combustion gases.
18. The ECAPS unit of claim 17, wherein the HVAC system includes a
condenser, wherein the condenser is radiatively shielded from an
outside of the ECAPS unit so as to reduce a thermal signature of
the ECAPS unit with respect to the condenser.
19. The ECAPS unit of claim 1, wherein the HVAC system is adapted
to enter a heat mode through a reverse-cycle with respect to the
cooling mode, the ECAPS unit further comprising electrical heating
elements adapted to increase a temperature of heated air expelled
from the ECAPS unit, the heating elements being powered by the
first DC power.
20. The ECAPS unit of claim 1, further comprising a
nuclear-biological-chemical (NBC) warfare sealed conditioned air
circuit.
21. The ECAPS unit of claim 1, wherein the first generator is
adapted to vary in speed with a variation in speed of the diesel
engine so as to output first AC power at a variable frequency.
22. The ECAPS unit of claim 1, further comprising a user interface,
wherein the user interface is adapted to permit a user to input
control commands to control a temperature of the outputted
conditioned air.
23. The ECAPS unit of claim 22, wherein the ECAPS unit is adapted
to automatically identify a temperature of air at a location remote
from ECAPS unit, and wherein the ECAPS unit includes a processor
that includes logic to automatically vary the at least one
parameter of the outputted conditioned air in response to the
identified temperature of air at remote location so as to
automatically effectively maintain a desired temperature of the air
at the remote location.
24. The ECAPS unit of claim 22, wherein the ECAPS unit includes
control logic adapted to automatically adjust speeds of one or more
compressors and/or one or more blowers based on a difference
between a sensed temperature of air and a set temperature set based
on a control command inputted by a user indicative of a desired air
temperature, wherein the control logic: automatically sets
respective compressor and/or blower speeds, upon a determination
that the difference is large, to speeds that are higher relative to
speeds set upon a determination that the difference is small;
automatically sets the respective compressor and/or blower speeds,
upon a determination that the difference is small, to speeds that
are lower relative to speeds set upon a determination that the
difference is large; and the ECAPS unit is adapted to automatically
lower the respective compressor and/or blower speeds as the
difference decreases.
25. The ECAPS unit of claim 1, wherein the ECAPS unit includes a
load management system which includes a control unit including
logic to automatically determine whether one or more loads drawing
export AC power and an HVAC system load, individually and/or
collectively, present a power demand exceeding a maximum power
available from the first generator, wherein the load management
system is adapted to automatically shed individual loads so as to
reduce the power demand to a level at or below the maximum power
available from the first generator, and wherein the load management
system is adapted to permit a user to pre-identify an order in
which individual loads are to be shed upon shedding of individual
loads.
26. The ECAPS unit of claim 1, wherein the first generator is an
inductionless generator, and wherein the HVAC system includes: one
or more variable-speed air conditioning compressors, one of which
is the variable speed compressor, respectively powered by
inductionless permanent magnet motors, one or more variable speed
condenser fans respectively powered by inductionless permanent
magnet motors; and one or more variable-speed evaporator fans
respectively powered by inductionless permanent magnet motors.
27. The ECAPS unit of claim 1, wherein the ECAPS unit is adapted
to: receive external AC power, rectify the external AC power to DC
power, and invert the DC power rectified from the external AC power
to export AC power; receive external low-voltage DC power; and
start the diesel engine with a starter drawing power only from the
external low-voltage DC power.
28. The ECAPS unit of claim 1, wherein the ECAPS unit includes an
internal self-diagnostic unit adapted to automatically identify
faults with the ECAPS unit and annunciate those faults to a user,
the automatically identified faults including insufficient power,
low fuel, low lubrication fluid, clogged air filtration, over
temperature of the ECAPS unit as a whole and/or one or more
sub-components, failure of electronic components, wherein the
internal self diagnostic unit is further adapted to identify a
deficient safety condition of the ECAPS unit and annunciate such to
the user.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application 60/822,717, filed Aug. 17, 2006, the contents of which
are incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Military and other emergency response services often need to
quickly establish temporary hospital and first-aid shelters to
treat injuries on location before patients are transported to more
permanent care facilities. These shelters are typically tents or
similar poorly insulated habitats that, when located in extremely
hot, cold or humid environments, sometimes present an inhospitable
environment for the occupants. In many areas, the effective
operation of a medical unit is not possible due to extreme
environmental conditions.
[0003] Typically, in areas where such shelters are provided, there
also exists a need to provide electrical power for lights,
computers, communication equipment and medical equipment inside the
shelter. Indeed, as field medical response becomes more
sophisticated, the amount of equipment dependent on reliable
electrical power continues to increase.
[0004] The military is shifting to rapid-deployment tactics where
the ability to quickly move into and out of a danger zone is
emphasized. With improved medical techniques relying on the ability
to get early treatment to the injured as quickly as possible, it is
now necessary to be able to transport and establish medical first
responder facilities right alongside the rapidly moving forces.
Transporting the required equipment by helicopter and small ground
vehicles like Humvees is now commonplace. Indeed, it is not
uncommon for "remote surgeries" to be executed, where field doctors
perform surgery while working with a surgeon stationed on another
continent, communications sometimes constituting visual images
communicated between the two locations via satellite(s).
[0005] Furthermore, federal, state and local governments and NGOs
face a very similar situation as they establish their own highly
flexible emergency response teams. These organizations desire to be
unburdened by their equipment and logistical support.
SUMMARY OF THE INVENTION
[0006] In a first exemplary embodiment of the present invention,
there is an environmental control and power system (ECAPS) unit,
comprising an HVAC system with at least one variable-speed
compressor driven by a first DC motor, wherein the HVAC system is
adapted to condition air and output the conditioned air, a
variable-speed diesel engine, a first generator mechanically
coupled to the diesel engine and adapted to vary in speed so as to
output first AC power at a variable frequency (the first generator
being a three-phase permanent magnet generator), a first
rectification assembly adapted to transform the first AC power from
the generator and/or external AC power to a first DC power, and a
first inverter assembly adapted to transform the first DC power to
an export AC power. In the first embodiment, the ECAPS unit is
adapted to direct the first DC power to the first DC motor to drive
the variable speed compressor, the ECAPS unit is adapted to vary,
in a controlled manner, at least one parameter of the outputted
conditioned air, and the ECAPS unit is a self-contained unit.
[0007] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
first DC motor is a brushless DC motor. In another exemplary
embodiment of the present invention, there is an ECAPS unit as
described above or below, wherein the first DC motor is a permanent
magnet motor. In another exemplary embodiment of the present
invention, there is an ECAPS unit as described above or below, the
first rectification assembly is configured to also transform the
first AC power and/or external AC power to a second DC power,
wherein the second DC power is at a substantially lower voltage
than a voltage of the first DC power. In another exemplary
embodiment of the present invention, there is an ECAPS unit as
described above or below, further comprising a second generator
mechanically coupled to the diesel engine, wherein the second
generator is configured to output power at a substantially lower
voltage than a voltage of the first AC power. In another exemplary
embodiment of the present invention, there is an ECAPS unit as
described above or below, wherein at least one of: (i) the power
outputted from the second generator is AC power, and the first
rectification assembly is adapted to transform the power outputted
from the second generator to DC power, (ii) the power outputted
from the second generator is AC power, and the ECAPS unit includes
a second rectification assembly, the second rectification assembly
being adapted to transform the power outputted from the second
generator to DC power, and (iii) the power outputted from the
second generator is DC power.
[0008] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
diesel engine is a three-cylinder turbo-charged common rail
injection aluminum engine.
[0009] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
first generator is a permanent magnet alternator having a capacity
about the same as that of the diesel engine. In another exemplary
embodiment of the present invention, there is an ECAPS unit as
described above or below, wherein the first generator has eight
magnetic poles of neodymium material and is wound on twelve
slots.
[0010] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
ECAPS unit includes at least one power buss circuit which directs
the first DC power to high voltage loads of the HVAC system
including: one or more variable-speed air conditioning compressor
motors, one of which is the variable speed compressor DC motor, one
or more variable speed condenser fan motors, and one or more
variable-speed evaporator fan motors.
[0011] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the one
or more variable-speed air conditioning compressors, the one or
more variable speed condenser fans, and the one or more
variable-speed evaporator fans are powered by permanent magnet
brushless DC motors. In another exemplary embodiment of the present
invention, there is an ECAPS unit as described above or below,
wherein the ECAPS unit is adapted to produce a second DC power,
wherein the second DC power is at a substantially lower voltage
than a voltage of the first DC power, wherein the ECAPS unit
includes at least two power buss circuits which respectively carry
the first and second DC powers to internal loads of the ECAPS unit
at substantially higher and lower voltage levels. In another
exemplary embodiment of the present invention, there is an ECAPS
unit as described above or below, wherein all of the internal loads
of the ECAPS unit are powered from DC power produced by the ECAPS
unit, the DC power produced by the ECAPS unit including the first
DC power and the second DC power.
[0012] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
first inverter assembly transforms the first DC power to the export
AC power such that the export AC power is a sine wave at least one
of 115, 120, 220, 230 and 240 volts and at least one of about 50
hz, 60 hz and 400 hz. In another exemplary embodiment of the
present invention, there is an ECAPS unit as described above or
below, wherein the HVAC has a capacity of 0-40 kw in heating mode
and 5,000-to 60,000 BTU/hr in cooling mode. In another exemplary
embodiment of the present invention, there is an ECAPS unit as
described above or below, further comprising a liquid-air heat
exchanger adapted to dissipate heat from the engine and the first
generator so as to decrease the external thermal signature of the
ECAPS unit, wherein heated components of the heat exchanger are
radiatively shielded from the outside of the ECAPS unit and the
ECAPS unit is adapted to direct cooling air discharged from the
heat exchanger in a manner to prevent external components of the
ECAPS unit from heating above an ambient temperature due to the
discharged cooling air.
[0013] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, further
comprising an exhaust system configured to exhaust combustion gases
from the diesel engine in a manner that decreases acoustic noise
and decreases the external thermal signature of the ECAPS unit,
wherein heated components of the exhaust system are radiatively
shielded from the outside of the ECAPS unit and the ECAPS unit is
adapted to discharge combustion gases exhausted from the ECAPS unit
in a manner to prevent external components of the ECAPS unit from
heating above an ambient temperature due to the discharged
combustion gases.
[0014] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
HVAC system includes a condenser, wherein the condenser is
radiatively shielded from an outside of the ECAPS unit so as to
reduce a thermal signature of the ECAPS unit with respect to the
condenser. In another exemplary embodiment of the present
invention, there is an ECAPS unit as described above or below,
wherein the HVAC system is adapted to enter a heat mode through a
reverse-cycle with respect to the cooling mode, the ECAPS unit
further comprising electrical heating elements adapted to increase
a temperature of heated air expelled from the ECAPS unit, the
heating elements being powered by the first DC power.
[0015] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, further
comprising a nuclear-biological-chemical (NBC) warfare sealed
conditioned air circuit. In another exemplary embodiment of the
present invention, there is an ECAPS unit as described above or
below, wherein the first generator is adapted to vary in speed with
a variation in speed of the diesel engine so as to output first AC
power at a variable frequency. In another exemplary embodiment of
the present invention, there is an ECAPS unit as described above or
below, further comprising a user interface, wherein the user
interface is adapted to permit a user to input control commands to
control a temperature of the outputted conditioned air. In another
exemplary embodiment of the present invention, there is an ECAPS
unit as described above or below, wherein the ECAPS unit is adapted
to automatically identify a temperature of air at a location remote
from ECAPS unit, and wherein the ECAPS unit includes a processor
that includes logic to automatically vary the at least one
parameter of the outputted conditioned air in response to the
identified temperature of air at remote location so as to
automatically effectively maintain a desired temperature of the air
at the remote location.
[0016] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
ECAPS unit includes control logic adapted to automatically adjust
speeds of one or more compressors and/or one or more blowers based
on a difference between a sensed temperature of air and a set
temperature set based on a control command inputted by a user
indicative of a desired air temperature, wherein the control logic:
automatically sets respective compressor and/or blower speeds, upon
a determination that the difference is large, to speeds that are
higher relative to speeds set upon a determination that the
difference is small, automatically sets the respective compressor
and/or blower speeds, upon a determination that the difference is
small, to speeds that are lower relative to speeds set upon a
determination that the difference is large, and the ECAPS unit is
adapted to automatically lower the respective compressor and/or
blower speeds as the difference decreases.
[0017] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
ECAPS unit includes a load management system which includes a
control unit including logic to automatically determine whether one
or more loads drawing export AC power and an HVAC system load,
individually and/or collectively, present a power demand exceeding
a maximum power available from the first generator, wherein the
load management system is adapted to automatically shed individual
loads so as to reduce the power demand to a level at or below the
maximum power available from the first generator, and wherein the
load management system is adapted to permit a user to pre-identify
an order in which individual loads are to be shed upon shedding of
individual loads. In another exemplary embodiment of the present
invention, there is an ECAPS unit as described above or below,
wherein the first generator is an inductionless generator, and
wherein the HVAC system includes: one or more variable-speed air
conditioning compressors, one of which is the variable speed
compressor, respectively powered by inductionless permanent magnet
motors, one or more variable speed condenser fans respectively
powered by inductionless permanent magnet motors, and one or more
variable-speed evaporator fans respectively powered by
inductionless permanent magnet motors. In another exemplary
embodiment of the present invention, there is an ECAPS unit as
described above or below, wherein the ECAPS unit is adapted to
receive external AC power, rectify the external AC power to DC
power, and invert the DC power rectified from the external AC power
to export AC power, receive external low-voltage DC power, and
start the diesel engine with a starter drawing power only from the
external low-voltage DC power.
[0018] In another exemplary embodiment of the present invention,
there is an ECAPS unit as described above or below, wherein the
ECAPS unit includes an internal self-diagnostic unit adapted to
automatically identify faults with the ECAPS unit and annunciate
those faults to a user, the automatically identified faults
including insufficient power, low fuel, low lubrication fluid,
clogged air filtration, over temperature of the ECAPS unit as a
whole and/or one or more sub-components, failure of electronic
components, wherein the internal self diagnostic unit is further
adapted to identify a deficient safety condition of the ECAPS unit
and annunciate such to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 presents an isometric view of an exterior of an ECAPS
unit according to an embodiment of the present invention.
[0020] FIG. 2 presents an isometric view from another side of the
ECAPS unit depicted in FIG. 1.
[0021] FIG. 3 presents an isometric view of an inside of the ECAPS
unit of FIG. 1.
[0022] FIG. 4 presents an isometric view from another side of the
ECAPS unit depicted in FIG. 3.
[0023] FIG. 5 presents an isometric view of a diesel engine
utilized in an embodiment of the present invention.
[0024] FIG. 6 presents an isometric view of a common rail injection
system utilized in the diesel engine of FIG. 5.
[0025] FIG. 7 presents components used in a generator according to
an embodiment of the present invention.
[0026] FIG. 8 presents an isometric view of a DC motor utilized in
the present invention.
[0027] FIG. 9 presents an architecture of the ECAPS unit according
to an embodiment of the present invention.
[0028] FIG. 10 presents an isometric view of another embodiment of
the ECAPS unit according to the present invention (dimensions in
inches).
[0029] FIG. 11 presents an interior view of the embodiment of FIG.
10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Referring now to FIGS. 1-4, a first embodiment of an
Environmental Control And Power System (ECAPS) unit according to an
exemplary embodiment of the present invention may be seen. In the
embodiments depicted in FIGS. 1-4, the ECAPS unit includes a
variable-speed diesel engine 30 and an HVAC system 110 which are
supported by a frame 23. In the embodiments presented in FIGS. 1-4,
the HVAC system 110 is powered by a generator 27 that is
mechanically coupled to the diesel engine 30, the generator 27
producing electrical power which is in turn is used to power the
HVAC system 110. According to the embodiments depicted in the
figures, the HVAC system 110, the generator 27 and the diesel
engine 30 are all packaged in a self-contained unit (the ECAPS unit
100).
[0031] In the embodiments depicted in FIGS. 1-4, the generator 27
is an alternator that outputs AC power at variable frequency. The
ECAPS unit includes a rectification assembly 31 which transforms
the AC power outputted from the generator 27 into DC power. An
inverter assembly 28 transforms DC power that was transformed from
the AC power produced by the generator 27 to export AC power, which
may be utilized by electrical devices remote from the ECAPS unit.
That is, in, the embodiment of the present invention depicted in
FIGS. 1-4, AC power produced by the generator 27 is rectified to DC
power and then inverted back to AC power for export from the ECAPS
unit. In the embodiments of FIGS. 1-4, the DC power rectified from
the AC power produced by the generator 27 is utilized to power all
components onboard the ECAPS unit. FIG. 9 presents a chart
detailing a high-level power management architecture according to
the embodiment of FIGS. 1-4.
[0032] Particular features of the embodiments presented in FIGS.
1-4 will now be described by way of example.
[0033] In an exemplary embodiment of the ECAPS unit of FIGS. 1-4,
the ECAPS unit includes an efficient light weight common rail
injection engine 30, as is exemplary depicted in FIG. 5. In some
embodiments, the common rail injection system (as is depicted by
way of example in FIG. 6, where the common rail injection system 50
is depicted) provides for efficient use of diesel fuel. The engine
30 depicted in FIG. 5 is a three-cylinder turbo-charged common rail
injection diesel aluminum engine, although in other embodiments,
different types of diesel engines may be utilized, especially those
that are rugged, reliable and efficient (as is the case with many
embodiments of the engine 30 depicted in FIG. 3). In some
embodiments, the use of turbo charging permits the ECAPS unit to be
altitude insensitive/relatively altitude insensitive. Turbo
charging may also provide for fuel efficiency and low emissions
from the engine 30. The engine 30 depicted in the figures is light
weight and relatively very compact. In embodiments utilizing the
engine 30 of FIG. 5, there is no wet stacking, and the engine is
designed for modular repair. Engine 30 is suitable for 5 kw to 30
kw long term operation, and these parameters may be different for
other embodiments. In view of the expectation that the ECAPS unit
will be utilized in low temperature environments, some embodiments
of the ECAPS unit include a diesel-fired hydronic heater that is
configured to pre-heat the diesel engine 30 to improve the
temperature operating range of the unit.
[0034] As detailed above, the engine 30 is mechanically coupled to
the generator 27. Rotational energy of the engine 30 is transferred
(e.g., through a coupling to the crankshaft of the engine 30) to
the rotational portion of the generator 27. The generator 27 is
configured to vary in speed and output AC power at a variable
frequency. (In some embodiments, the generator varies in speed in
direct proportion to a variation in speed of the engine 30.) In the
embodiment depicted in the figures, the generator 27 is a
three-phase permanent magnet generator. In the exemplary embodiment
depicted in FIGS. 1-4, the generator 27 has a capacity that is
about the same as that of the diesel engine 30, although in other
embodiments of the present invention, the capacity of the generator
27 may vary with respect to that of the engine 30. In some
embodiments, the generator 27 has eight magnetic poles of neodymium
material and is wound on twelve slots.
[0035] FIG. 7 presents exemplary components of the permanent magnet
AC generator 27 utilized in FIGS. 1-4. As noted above, the
generator 27 is configured to varying speed with variation and
rotational speed of a diesel engine 30. This allows AC power to be
outputted from the generator 27 at a variable frequency. That is, a
variation in the speed of the engine 30, in some embodiments, will
correlate to a variation in the frequency of the AC power outputted
by the generator 27. Some embodiments of the generator 27 utilized
in the present invention are about 80% or so smaller and lighter
than synchronous units. Efficiency of the generator 27 is about 96%
which allows for less fuel to be utilized and less heat to be
dissipated. A 100% "potted" coil is used in the embodiments
depicted of the generator 27. In some embodiments, this permits the
generator 27 to be impervious/relatively impervious to the
environment.
[0036] In some designs of the ECAPS unit of the present invention,
the generator 27 may be operated in parallel with other generators,
especially in the event that higher capacity is needed.
[0037] In some embodiments of the ECAPS unit according to the
present invention, as load fluctuates, the voltage produced by the
generator 27 may also fluctuate. This may be compensated for, in an
exemplary embodiment, by changing the speed of the generator 27. In
this regard, the engine/generator assembly may be configured such
that the engine 30 slows down as load on the generator 27 is
reduced, and visa-versa.
[0038] Some embodiments of the present invention further include a
second generator 33 (see FIG. 3), in addition to the primary
generator 27. (The second generator 33 may be, for example, a small
engine-driven alternator, a DC-to-DC converter, or a secondary
winding on the main generator, etc.) This second generator 33 is
also mechanically coupled to the diesel engine 30 (in the
embodiment depicted in FIG. 3, the second generator 33 is coupled
via a belt, although mechanical coupling via a torque converter or
the like (parts mechanically coupled by fluid), gears, etc., may
also be used). In some embodiments, this second generator 33 is
configured to output power at a substantially lower voltage than
the voltage that is outputted by generator 27. By way of example
only and not by way of limitation, if the primary generator 27
outputs voltage at 110 volts, the second generator 33 may produce
power at a voltage of, for example, 12 or 24 volts, etc. In some
embodiments of the present invention, the power outputted from the
second generator 33 is AC power. However, in other embodiments of
the present invention, the power outputted from the second
generator 33 may be DC power. In embodiments where the power
outputted from the generator 27 is AC power, the rectification
assembly 31 may be used to rectify AC power from the second
generator 33 to DC power. (The rectification assembly 31 may be a
passive full bridge rectifier, or in other embodiments, may be an
active rectification circuit.) Still, in other embodiments of the
present invention, a separate rectifier assembly 34 is used to
transform the power outputted from the second generator 33 to DC
power. In embodiments of the present invention where the second
generator 33 is a DC power generator, the power may not need
rectification. Other embodiments of the present invention may
include additional generators as well (additional AC generators
and/or additional DC generators).
[0039] In the embodiment of the present invention of FIGS. 1-4, the
rectification assembly 31 is used to transform AC power produced
from the generator 27 to DC power. In some embodiments,
rectification assembly 31 is configured to transform AC power
produced by the generator 27 into two separate DC powers of
different voltages (e.g., one high voltage, one low voltage). In
some embodiments of the present invention the rectification
assembly 31 is used to produce three or more different DC powers,
each of which may be at different voltages. As will be discussed in
greater detail below, the low voltage DC power is utilized to
power, for example, components of the user interface unit 1
(including a user interface screen) that do not require high
voltage. Conversely, the high voltage DC power is utilized to power
components which require high voltage DC power (e.g., HVAC motors,
etc.).
[0040] Many embodiments of the present invention are configured to
not only generate AC power from the rotational energy produced by
the diesel engine 27, but are also designed to receive AC power
from an external source. Accordingly, the ECAPS unit can receive
power from an external generator and/or an external power pole,
which may be desirable in a scenario where the onboard diesel
generator may be unavailable and/or the generator cannot be used to
produce enough power and/or in a scenario where power from the
generator 27 is unwanted. In some embodiments, the rectification
assembly 31 is configured to convert this AC power from an external
source to DC power, just as it converts (or in an analogous manner
to converting) the AC power produced by the generator 27 to DC
power. It will be noted that the rectification assembly 31 may
include one, two or more rectifiers. The number of rectifiers
needed will be determined based on the requirements of a particular
ECAPS unit to be built. In this regard, a rectification assembly
may include two rectifiers, the first rectifying the power from the
generator 27 and the second rectifier rectifying power from the
external power source. Indeed, in some embodiments, a rectifier
assembly may include three rectifiers with the third rectifier
rectifying power from the second generator 33. Of course, separate
rectifier assemblies may be utilized for each individual generator.
Also, in some embodiments, the same rectifier may be used to
rectify the AC power produced by generator 27 and the external AC
power. Any device or assembly of devices that will permit the
rectification of AC power produced by the onboard generators and
will permit the rectification of AC power from external power
sources may be utilized to practice the present invention. (Also
note that a rectification assembly may include a plurality of
rectification assemblies.)
[0041] The ECAPS unit includes an external power input connection 9
so that the ECAPS unit can receive power from an external generator
and/or an external power pole.
[0042] The ECAPS unit depicted in FIGS. 1-4 includes at least two
power bus circuits 35, 36, which respectively carry the high
voltage and low voltage DC power (from the rectification
assembly(s)) to internal loads of the ECAPS unit. By way of
example, bus 35 carries a DC voltage at 110/220 volts to the
compressor motor 32 of the HVAC system (discussed in greater detail
below), and bus 36 carries a voltage of 12 volts to the user
interface unit 1 (also discussed in greater detail below).
[0043] ECAPS unit 100 includes an inverter assembly 28. Inverter
assembly 28 transforms the DC power rectified by one or more of the
rectifier assemblies to AC power which may be exported from the
ECAPS unit 100 to power, for example, lighting, computers, etc.,
remote from the ECAPS unit 100. In an exemplary embodiment of the
present invention, the inverter 28 is used to transform DC power to
AC power in the form of a sine wave at, for example, 115, 120, 220,
230 and 240 volts, which may later be exported from the ECAPS unit
as export power. The inverter 28, according to some embodiments of
the invention, provides sine wave AC electrical power with minimum
voltage ripple. The frequency at which this exported power is at
maybe 50 hertz, 60 hertz and/or 400 hertz, etc. The voltages and
frequencies in some embodiments may be controlled by a user via
imports from the user interface unit 1. Other voltages and/or
frequencies may be set by the user than those just specified, in
some embodiments. In the embodiment depicted in FIGS. 1-4, voltages
and frequencies of power exported from the ECAPS unit 100 are the
same as and/or similar to that needed by common components that
would be expected to use power from an ECAPS unit or the like.
[0044] The ECAPS unit 100 includes connections 8 to permit exterior
connection to AC power exported from the ECAPS unit 100 (power from
the inverter 28).
[0045] Not only can some embodiments of the ECAPS unit 100
according to the present invention receive external AC power and
rectify and then invert the power to export AC power, some
embodiments of the ECAPS unit 100 are configured to receive
external low-voltage DC power as well. (Note the socket receptacle
7 for the low voltage DC power.) In some embodiments of the present
invention, this low voltage DC power is utilized to start the
diesel engine 30 in a scenario where the battery of the ECAPS unit
is dead or otherwise has insufficient charge to crank the diesel
engine 30. In some embodiments, this low voltage DC power may be
obtained from another separate ECAPS unit 100 according to the
present invention. Accordingly, some embodiments of the ECAPS unit
100 according to the present invention include the ability not only
to export AC power, but also to export DC power, and thus may have
an outlet in the form of a receptacle or the like for exporting
this low voltage DC power.
[0046] Features of the HVAC system 110 of the ECAPS unit 100
according to the exemplary embodiment depicted in FIGS. 1-4 will
now be described. In the embodiment depicted in FIGS. 1-4, the HVAC
system 110 includes variable speed components. These components are
typically driven by variable speed motors. By way of example only
and not by way of limitation, a variable speed compressor 20 is
powered by a variable speed DC motor 32, which may be a brushless
inductionless DC motor. In some embodiments of the ECAPS unit 100,
the compressor speed may vary from 1,000 to 7,000 rpm. Further by
way of example, a variable speed condenser fan/blower 15, located
adjacent condenser/gas-to-air heat exchanger 13, is also powered by
a variable speed DC motor (blower speed may vary from 300 to 4,500
rpm). Still further, the HVAC system 110 according to some
embodiments of the present invention may utilize one or more
variable speed evaporator fans/blower 19 located adjacent
evaporator/liquid-to-air heat exchanger 21. In the exemplary
embodiment depicted in the figures, the DC motors powering the HVAC
components just mentioned receive DC power through the power bus
35, which directs high voltage power to the high voltage loads of
the ECAPS unit 100, such as the motors of the HVAC system, along
with, for example, motors for the engine radiator/liquid-to-air
heat exchanger blower 16 for the engine radiator 17. In the
embodiments depicted in FIGS. 1-4, the motors powering the HVAC
unit components are permanent magnet brushless DC motors. An
exemplary embodiment of a brushless DC motor 32 used to power the
compressor 20 may be seen in FIG. 8. The ECAPS unit 100 according
to the embodiment depicted in the figures is configured to direct
DC power directly to the motors of the HVAC system. These motors
are typically inductionless motors (i.e., in some embodiments,
induction motors are not utilized). Inductionless motors used in
the embodiment depicted in the figures may be up to 70% smaller and
lighter than induction motors. The motors are, in some embodiments,
about 97% efficient and variable in speed. Further, the motors used
in some embodiments exhibit little or no inductive start up surge
when the motors are started. In the exemplary embodiment depicted
in the figures, the motors tolerate +/-50% voltage fluctuations,
although in other embodiments, more or less robust motors may be
utilized. In many embodiments, inductionless permanent magnet
motors are utilized.
[0047] Operational performance characteristics are the HVAC system
110 according to some of the embodiments of the present invention
will now be described.
[0048] The HVAC system 110 utilized in the ECAPS unit 100 depicted
in FIGS. 1-4 is a reverse cycle HVAC system. The HVAC system 110
may operate in a heating mode and may also operate in a cooling
mode. When in the heating mode, the HVAC system 110 may have a
capacity of about 0-40 kilowatts. When in the cooling mode, the
HVAC system 110 may have a capacity of about 5,000 to 60,000 BTU
per hour. The HVAC system is adapted to enter a heat mode through a
reverse-cycle with respect to the cooling mode.
[0049] The embodiment of the ECAPS unit 100 present in FIGS. 1-4 is
designed to permit the ECAPS unit to be placed into fluid
communication with a remote structure, such as a tent, a building,
a vehicle, a trench that may be relatively enclosed, etc., by
attaching tubing/piping, etc., to duct 11, through which the HVAC
system discharges conditioned air. (Note that, conditions
permitting, a return tube/pipe, etc., in fluid communication with
the remote structure, may be connected to duct 12, through which
the HVAC system receives return air from the remote structure to
which conditioned air is being delivered.) In this manner, the
ECAPS unit may be placed a desirable distance from the structure in
which climate is desired to be controlled. In this regard, because
the ECAPS unit 100 may be used to deliver conditioned air a
considerable distance from the ECAPS unit 100, the embodiment of
the ECAPS unit 100 of FIGS. 1-4 is configured to identify air
temperature at a location remote from ECAPS unit. For example, a
wireless (or wire based) sensor may be placed in the remote
structure to monitor environmental conditions (e.g., temperature
and/or humidity, etc.) and send signals which may be received and
analyzed by a control system onboard the ECAPS unit indicative of
the monitored condition.
[0050] In view of the sophisticated nature of the ECAPS unit
according to FIGS. 1-4, some embodiments of the ECAPS unit include
a processor with logic (simple circuit, complex circuit, software,
firmware, etc.) that permits the ECAPS unit to automatically vary
parameter(s) (e.g., temperature, humidity, flow rate, etc.) of the
conditioned air being outputted by the unit in response to the
monitored condition so as to maintain a desired condition (e.g.,
temperature) of the air at the remote structure. For example, the
control logic of the ECAPS unit may be such that the unit
automatically adjusts speeds of one or more of the HVAC compressors
and/or one or more of the HVAC blowers based on a difference
between a sensed temperature of air and a set temperature set based
on a control command inputted by a user into the user interface 1,
the control command being indicative of a desired air temperature
in the remote structure. In an exemplary embodiment, the control
logic may automatically set compressor and/or blower speeds, upon a
determination that a difference between desired temperature and
current temperature is large, to speeds that are higher relative to
speeds set upon a determination that the difference between the
desired temperature and the current temperature is small. The
control logic may also be configured to automatically set the
respective compressor and/or blower speeds, upon a determination
that the difference between desired and current temperature is
small, to speeds that are lower relative to speeds set upon a
determination that the difference between desired and current
temperature is large. Further, embodiments of the ECAPS unit
include logic to lower the respective compressor and/or blower
speeds as the difference decreases, and, alternatively, increase
the respective compressor and/or blower speeds as the difference
increases, etc. In this regard, the ECAPS unit according to the
present invention may include logic based on theoretical and/or
empirical analysis of how some parameters (e.g., compressor speed)
may be adjusted in view of adjusting other parameters (e.g., blower
speed) to achieve a desired environmental condition.
[0051] Embodiments of the ECAPS unit 100 may include a power
management system as part of the control unit/control system 18.
Such a system may include logic to determine whether one or more
loads drawing export AC power and/or an HVAC system load,
individually and/or collectively, present a power demand exceeding
a maximum power available of the ECAPS unit 100. In an exemplary
embodiment, the load management system enables the ECAPS unit to
shed individual loads so as to reduce the power demand on the ECAPS
unit to a level at or below the maximum power available from the
unit. Accordingly, the embodiment presented in FIGS. 1-4 permits a
user to input into the user interface 1 exactly which individual
loads are to be shed in what order in the event that the ECAPS unit
enters a "shed-load" regime. For example, a user may input
information into the unit such that power to a light or a
communication device should be shed instead of shedding power to a
medical device, etc.
[0052] It is noted that in some embodiments of the present
invention, the ECAPS unit is further configured with electrical
heating elements 37 that are utilized to increase a temperature of
air expelled from the HVAC system. In an exemplary embodiment
according to the present invention, these heating elements 37 are
powered by DC power from the power bus 35, as the elements are high
voltage elements. The electrical heating elements 37 are configured
to give the ECAPS unit a boost in heat output in environmental
conditions where the reverse cycle of the HVAC system is not
sufficient such as may be the case in extremely cold
environments.
[0053] The ECAPS unit of FIGS. 1-4 includes a user interface 1
(which includes an emergency shut off button 2). The user interface
1 is configured to permit a user to input control commands to
control a temperature of the outputted conditioned air, control a
humidity of the conditioned air, control a speed of the engine
and/or enable/disable export of electrical power, among other
things. In some embodiments, the user interface 1 is configured to
display current status of various components onboard the ECAPS unit
100, such as, for example, engine temp, engine RPM, oil pressure,
power load on the ECAPS, fuel level, estimated run time,
maintenance data (e.g., oil change warranted, overhaul warranted,
tune-up warranted and/or shut-down warranted), and/or warning
information.
[0054] As will be readily understood from the background section
above, some embodiments of the ECAPS unit according to the present
invention will be utilized in battlefield areas/forward deployed
locations, where hostilities have and/or are and/or are likely to
commence. Accordingly, some embodiments of the present invention
are designed to minimize a thermal signature produced by the ECAPS
unit during operation of the ECAPS unit. In an exemplary
embodiment, the ECAPS unit 100 includes an exhaust system that is
configured to exhaust combustion gases from the diesel engine 30 in
a manner that decreases the external thermal signature of the ECAPS
unit. (Note that the exhaust system may also be configured to
decrease acoustical noise produced by the generator. (See engine
muffler 25.)) In this exemplary embodiment, components of the ECAPS
system that are heated during operation of the ECAPS unit are
radiatively shielded from the outside of the ECAPS unit (in some
embodiments, these components cannot be seen from the outside).
Further, in some embodiments of the present invention, the ECAPS
unit is adapted to discharge combustion gases exhausted from the
ECAPS unit (such as, for example, through engine exhaust pipe 26
which leads to exhaust port 5) in a manner so as to prevent
external components of the ECAPS unit from heating above an ambient
temperature due to the discharged combustion gases. In this regard,
the figures provide exemplary schematics of one design of an ECAPS
unit that accomplishes the just mentioned design features. (Note as
well some embodiments permit an extension to be placed onto the
exhaust port 5 so as to channel exhaust gases further from the unit
100.) Accordingly, some embodiments of the present invention permit
HVAC system operation and/or power generation to be accomplished
while leaving a relatively low thermal signature. In some
embodiments, the low thermal signature is obtained by limiting the
amount of waste heat produced and/or by dissipating heat evenly
behind a shield, thereby substantially avoid high point-source
discharge. (Also, the efficient operation of the ECAPS unit
according to the present invention also affords a reduction in the
thermal signature in that it produces less waste heat than would
otherwise be produced.) Additionally, because the HVAC and power
generator are packaged together, more shielded space is available
to dissipate heat before being discharged from the ECAPS unit/to
avoid hot spots. Accordingly, some exemplary embodiments of the
ECAPS unit operate with a high thermal efficiency and therefore,
has less heat to dissipate.
[0055] It will be understood that in addition to the diesel engine
30, other components of the ECAPS unit 100 produce/radiate thermal
energy. By way of example, and not by way of limitation, the HVAC
system condenser 13 will radiate heat. Accordingly, the embodiment
depicted in the figures present a configuration where the condenser
13 is likewise radiatively shielded from the outside of the ECAPS
unit in a manner that reduces the thermal signature of the ECAPS
unit, at least with respect to the condenser 13. The ECAPS unit 100
also includes a engine radiator 17 (liquid-to-air heat exchanger)
which is configured to dissipate thermal energy/heat removed from
the engine 30. In some embodiments, the radiator 17 is also
configured to dissipate thermal energy removed from the generator
27 (note that a separate radiator may also be used to dissipate
thermal energy from the generator 27). Exemplary designs of the
ECAPS unit 100 are such that cooling air discharged from the
radiator 17 is discharged in a manner that prevents external
components of the ECAPS unit from heating above the ambient
temperature due to the discharged cooling air. In keeping with the
design feature that the ECAPS unit leaves a reduced/minimized
thermal footprint, the heated components of the heat
exchanger/radiator 17 are radiatively shielded from the outside of
the ECAPS unit (in some embodiments, these components cannot be
seen from the outside).
[0056] It will be noted that in some embodiments of the present
invention, the fuel tank 14 with fuel fill port 4 (shown capped) is
integral to the ECAPS unit and is nestled between the engine 30 and
the HVAC with a fuel lubricity additive fill port 3 (shown capped)
leading to fuel lubricity additive reservoir 24 so that lubricating
fluid may be added to the fuel if necessary. In alternate
embodiments, the ECAPS unit includes a storage reservoir and
metering pump that automatically injects a measured amount of
lubricating agent into the fuel tank (to improve the lubricity of
the fuel when using low-lubricity fuels). Other embodiments may
also include an oil fill port with cap (not shown) for adding
lubrication fluid to the engine 30 in more traditional manner.
Various embodiments of the ECAPS unit 100 are such that the fuel
tank 14 is of sufficient volume to provide continuous operation at
the expected loads for a sufficient duration. The fuel tank 14 has,
in some embodiments, a fuel filler port 14 (shown capped) located
on the top in a manner that fuel may be added to the tank from the
outside. In regard to fueling, some embodiments of the ECAPS unit
are designed such that the diesel engine 30 can run on a variety of
types of fuel. In this regard, a use scenario may include utilizing
low-lubricity fuels such as, for example, JP-8, etc.
[0057] Embodiments of the invention include a sound reducing and
environmentally protective enclosure 6 to which forklift runners 10
are affixed. In some embodiments these runners 10 are permanently
located to the enclosure cover/ECAPS unit or another embodiment
they may be removable. The forklift runners 10 aide in transport of
the ECAPS unit by forklift.
[0058] In the embodiment depicted in FIG. 4, an HVAC filter/dryer
22 is present. In an alternate embodiment of the ECAPS unit, the
HVAC system includes a humidity control section that allows a
humidity level to be maintained. The user interface 1 may permit a
user to enter a desired humidity level and/or to simply indicate a
desire to adjust humidity in a certain direction. The humidity
control section would include a humidity sensor coupled to closed
loop or open loop control system to control the humidity level. In
view of the possibility that some ECAPS units may be used during
armed conflicts, some embodiments of the ECAPS unit 100 include a
nuclear-biological-chemical (NBC) warfare sealed conditioned air
circuit, although some embodiments may simply seal the conditioned
air circuit against biological and/or chemical warfare agents.
Accordingly, in some embodiments of the present invention, NBC
filters may be utilized, and the ECAPS unit is thus configured to
receive such filters. As would be understood by one skilled in the
art, some embodiments of the present invention configured for use
in an NBC environment are hardened against NBC warfare agents.
[0059] Again, in many embodiments of the ECAPS unit 100 according
to the present invention the AC power from the inverter 28 is used
only for export power. That is, it is not used to power onboard
systems of the ECAPS unit 100. (In many embodiments, all electrical
devices on the ECAPS unit are powered from the internal high
voltage and/or internal low voltage DC buses.)
[0060] Some embodiments of the present invention provide utility in
that it provides a clean and stable 50 hz or 60 hz AC power in one
or more voltages. Further, some embodiments of the present
invention are fuel efficient, which is often useful in emergency
situations where fuel may be in short supply. Some embodiments of
the present invention obtain fuel efficiency by adjusting the speed
of the diesel engine/generator to match or otherwise correlate to
the load placed on the generator. That is, the diesel
engine/generator used in at least some embodiments of the present
invention do not continue to operate at full speed when different
loads are placed on the generator. By way of example only and not
by way of limitation, the diesel engine may operate at 1800 RPM
when heavy loads are applied to the ECAPS unit, but then operate at
1000 RPM when medium loads are applied to the ECAPS unit. Of
course, other embodiments may operate at a higher and/or lower RPM
than 1800 at such high loads, and/or operate at a higher and/or
lower RPM than 1000 at medium loads, etc. These embodiments may be
practiced as long as they permit the ECAPS unit to be relatively
closely and/or efficiently matched to the operating conditions
exposed to the unit. In this regard, in some embodiments of the
present invention, by operating the generator and the HVAC
compressors, blowers, etc., at variable-speeds, the capacity of
each can be closely matched to the load and thereby optimized for
maximum efficiency, thus improving fuel efficiency.
[0061] Some embodiments of the present invention permit the ECAPS
unit to be more easily transported by air, land, and/or water
during an emergency. In this regard, some embodiments of the
present invention are relatively small, and are made relatively
small, for example, through the use of non-induction motors,
non-induction generators. In some embodiments, permanent magnet
generators, motors, etc., are utilized, which produce much greater
power with less weight and size. (Some embodiments utilize all
permanent magnet components, while others use a combination of
components.) Also, the relative efficiency of the engine,
generator(s), motor(s), etc., affords fuel efficiency which permits
a reduction in weight and/or size of the ECAPS unit, in that less
fuel must be carried (more fuel adding to the total weight and size
of the unit). Also, weight reduction, size reduction, and/or ease
of transportability are relatively achieved by packaging the HVAC
system and the export power generation system together in one unit.
(Logistics are also relatively simplified.)
[0062] Some embodiments of the present invention eliminate or
otherwise sufficiently mitigate the occurrence of voltage sag
conditions ("brown out"). It has been determined that sometimes
excessively long or undersize cables are used to get the power to
locations where the power is required. As a result, a significant
voltage drop can be induced when the load is applied. This is
significant because compressors, computers, and other sensitive
equipment such as X-ray machines, etc., can fail/overheat when
powered under the design voltage. Accordingly, embodiments of the
present invention address this phenomenon by permitting an external
power source to be first connected to the ECAPS unit, which
rectifies all of the external power to DC power. The power which is
exported from the ECAPS unit (for use by external appliances) is
inverted from the rectified DC power and, in the process, corrected
back to the proper AC voltage level. In scenarios where the
external power is being used to operate the HVAC system of the
ECAPS unit (i.e., instead of powering the HVAC system from the
generator driven by the engine), operating all of the components
from the rectified external power (the DC power) affords, in some
instances, immunity from voltage drops in the external power.
[0063] Some embodiments of the present invention are designed to
meet or exceed some or all of the operating characteristics of
current FDECU & 30 kw TQGs. Some embodiments of the present
invention provide 15 kw "clean" exportable 120/240 vac power,
65,000 BTU/hr of air conditioning and heat, while
avoiding/eliminating "brownouts" of sensitive equipment, without
"wet stacking" of generators at low loads. Some embodiments are
designed to have relatively low emissions while permitting
relatively swift field repair. It is noted that an exemplary
embodiment of the ECAPS unit 100 according to the present invention
has a weight of about 1590 pounds with a cube volume of 53 cubic
feet. Some embodiments of the present invention utilize a composite
frame and enclosure of low weight and high durability, and utilizes
state-of-the-art self-diagnostics with pre-failure notification. In
this regard, an exemplary internal self-diagnostic unit utilized
with the ECAPS unit 100 may be configured to identify faults with
the ECAPS unit and annunciate those faults to a user. Identified
faults may be, by way of example only and not by way of limitation,
include insufficient power, low fuel, low lubrication fluid,
clogged air filtration, over temperature of the ECAPS unit as a
whole and/or one or more sub-components, failure of electronic
components. The internal self diagnostic unit may identify a
deficient safety condition of the ECAPS unit and annunciate such to
the user.
[0064] Some embodiments permit expansion of capacity up to 200 kw,
while others even more.
[0065] An exemplary scenario of use of an ECAPS unit according to
an exemplary embodiment of the present invention will now be
described. Accordingly, any embodiment of the ECAPS unit which may
be designed and fabricated to permit the following exemplary
scenario to be executed is considered within the scope of the
present invention. (Indeed, it is noted that the present invention
includes any self-contained unit with devices adapted to permit any
or all of the features/capabilities described herein to be
performed/executed.)
[0066] In a typical example of use, the ECAPS unit is first removed
from a transport vehicle by forklift or other lifting machine and
set down within about 5 meters of an emergency treatment shelter,
such as, for example, a tent. Two flexible air ducts would be
installed to connect the inlet and outlet 11 and 12 of the ECAPS
unit to air ports on the tent. These ducts provide a conduit for
circulating air from the tent, through the HVAC system 110 of the
ECAPS unit 100 for heating or cooling (as desired) and back into
the tent. The ducts utilized in this scenario are insulated and
about 12'' to 20'' in diameter, although in other scenarios of use,
non-insulated ducts are used (indeed, corrugated piping might be
used in an exemplary scenario).
[0067] Depending on the risk involved (proximity of the tent to the
ECAPS unit, wind direction, etc.), an extension may or may not be
added to the exhaust outlet of the diesel engine to reduce the risk
of CO entering the tent.
[0068] Next diesel fuel is added to the integral fuel tank. If a
low lubricity fuel such as JP 8 is used, an optional metering pump
automatically pumps the correct amount of lubricating additive from
an on-board reservoir into the fuel.
[0069] The operator next programs the desired temperature into the
user interface 1 and starts the system. If the optional remote
sensor is being utilized, it is placed in a location of critical
temperature control within the tent--wirelessly transmitting the
sensed temperature back to the control unit 18 on the ECAPS system.
If the remote sensor is not being used, the temperature of the air
will be read as the air passes through the ECAPS unit and that
temperature is used to control the ECAPS unit.
[0070] The running engine now turns the permanent magnet generator
27 which in turn produces an AC voltage at a frequency dependent on
the speed of rotation. This AC power passes through a passive full
bridge rectifier, or in other embodiments, an active rectification
circuit, and is converted to DC power. This DC power is fed to the
main (higher voltage) power buss. A second device (for example, a
small engine-driven alternator, a DC-to-DC converter, or a
secondary winding on the main generator, etc.) produces a smaller
amount of DC power at a lower voltage level.
[0071] The primary (higher voltage) buss, now energized, begins to
provide the main power to the fans, blowers, compressors,
resistance heaters, etc., as well as the export power inverter. The
secondary (lower voltage) buss begins charging the engine starting
battery and provides a lower voltage to the control circuits.
[0072] With the generator running and the desired temperature set,
the ECAPS unit automatically adjusts the speed of the compressors
and blowers based on the delta between the actual measured
temperature and the desired set point. A higher delta results in a
higher compressor and blower speed thereby providing higher
capacity to rapidly move the temperature toward the set point. As
the temperature nears the set point, the compressor and blowers
slow to reduce the system capacity. Ultimately, the control system
onboard the ECAPS unit adjusts the HVAC capacity to match that
required to maintain the set point temperature. It is noted,
however, some embodiments of the ECAPS unit permit a user to
override the control logic in the event that the control logic is
malfunctioning (as may be the case after a detonation producing an
electromagnetic pulse). A user may override the system with a
simple switch, or, alternatively, may rig bypasses around the
control system and/or otherwise make adjustments to components
himself or herself.
[0073] As the HVAC system changes capacity to match the required
set point, the electrical load on the generator changes. To
optimize fuel efficiency, the generator adjusts speed to provide
the required power efficiently.
[0074] The ECAPS begins to provide clean, exportable AC power for
non-internal devices via the DC-to-AC inverter. In this exemplary
scenario, powered devices such as lights, computers, communications
equipment, decontamination equipment and electrically powered
medical devices, etc., are connected to the ECAPS unit. These
devices are plugged into a socket provided on the front of the
ECAPS unit. The power exported from the unit is drawn from the
primary DC buss. The additional load on the generator is taken into
account by the controls system when optimizing the engine speed for
fuel efficiency.
[0075] In the event that the total of the exportable AC power and
the HVAC system load exceed the power available from the generator,
load will be shed according to the preferences entered by the
operator via the user interface and/or a pre-programmed regime.
[0076] FIGS. 10 and 11 present an alternate layout of an alternate
embodiment of the ECAPS unit 100 according to the present
invention.
[0077] Given the disclosure of the present invention, one versed in
the art would appreciate that there are other embodiments and
modifications within the scope and spirit of the present invention.
Accordingly, all modifications attainable by one versed in the art
from the present disclosure within the scope and spirit of the
present invention are to be included as further embodiments of the
present invention.
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